Integral prefinished wood base door and split jamb assembly

ABSTRACT

This invention relates to a door and jamb assembly and more particularly to one of a split, tongue and groove, jamb construction having a prefinished wood base. The jamb assembly includes male and female sections joined in a tongue and groove fashion for adaptability to various wall thicknesses, and each having a casing member and jamb member, and the female section having a doorstop, formed integrally for assembly as a one-piece unit. The entire jamb assembly is prefinished in vinyl, and the door is prehung on the female section.

@nited States Patent [1 1 Mundy 1 Sept. 11, 1973 1 1 lNTEGlRAL PREFINISHED WOOD BASE DOOR AND SPLIT JAMB ASSEMBLY [75] lnventor: William L. Mundy, St. Louis, Mo.

[73] Assignee: Permaneer Corporation, Maryland Heights, Mo.

[22] Filed: Jan. 3, 1972 [21] Appl. No.: 215,172

[52} U.S. Cl 49/380, 49/505, 52/212 [51] Int. Cl E06b 1/10 [58] Field of Search 49/380, 501, 504,

{56] References Cited UNITED STATES PATENTS 1,440,615 1/1923 Meyercordnu, 52/631 2,557,412 6/1951 Clements 52/631 X 3,119,156 1/1964 Salter, Jr r 52/211 3,345,780 10/1967 McGhee 52/211 X 3,654,053 4/1972 Toedter 52/631 FOREIGN PATENTS OR APPLICATIONS 1,509,258 8/1963 Germany 49/504 Primary Examiner-Kenneth Downey Attorney-.lohn M. Howell 57 ABSTRACT This invention relates to a door and jamb assembly and more particularly to one of a split, tongue and groove, jamb construction having a prefinished wood base. The jamb assembly includes male and female sections joined in a tongue and groove fashion for adaptability to various wall thicknesses, and each having a casing member and jamb member, and the female section having a doorstop, formed integrally for assembly as a onepiece unit. The entire jamb assembly is prefinished in vinyl, and the door is prehung on the female section 7 Claims, 6 Drawing Figures INTEGRAL PREFINISI'IED WOOD BASE DOOR AND SPLIT JAMB ASSEMBLY SUMMARY OF THE INVENTION There has long been a need to minimize the installation and finishing time required at the job site on doors and door-jambs.

The door and jamb assembly of this invention has among its advantages a wood base construction and vinyl finish for attractiveness and durability, a split tongue and groove construction for adaptability to a variety of wall widths, preformed casing, jamb, and doorstop as integral units, and a prehung door as part of the assembly, all of which minimize installation time and cost and eliminate finishing at the job site, as well as provide a near perfect fit every time.

The jamb assembly generally includes a male section having casing and tongue members, and a female section having casing and groove members, each of the male and female sections being of prefinished, vinyl covered wood base construction and preformed as an integral unit. Also formed integrally with the female section is a doorstop. A door is prehung to the female section on suitable hinges and prefinished as desired.

Hence, it is the general object of this invention to provide a door and jamb assembly that is preformed and prefinished at the factory to provide a minimum of installation time and cost and eliminate the need for finishing at the job site.

Other objects will become apparent from the following drawings and detailed description of the invention.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a frontelevation view of the door and jamb assembly of this invention shown installed in the rough opening of a wall;

FIG. 2 is an enlarged view in section taken along the line 2-2 of FIG. 1;

FIGS. 3 and 4 are isometric views showing the manner in which the female and male sections, respectively, of adjacent jamb segments are joined and alignedat a mitered corner; and I F IGS.5 and 6 are end views of vinyl covered boards used for describing the manner in which the sembly is formed.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT Referring to the drawings there is shown a door and jamb assembly 10 as mounted in a doorway openingin a wall 12. The wall 12 might, for example, be of conventional construction of wood frame members, such as two-by-fours 13 with drywall covering 14 on. each side. The assembly 10 has a left side jamb segment 15, a right side jamb segment 16, and a top jamb segment or header 17 (as viewed in FIG. 1) joined and aligned at mitered joints 20 and 22 with screws 24 (FIGS. 3 and 4) or other suitable means. A door 30 is mounted on hinges 32 to the left jamb segment as will be described.

Each of the jamb segments 15, 1'6, and 17 are of generally the same construction as best shown in FIG. 2, with each segment having a male portion 36 and a female portion 38. The male portion 36 has a casing member 40 having an end 42 that rests against one side of the wall 12 and is formed with sections 44, 45, and 46 and joints 47, 48, and 49 as will be described. The

jamb ascasing member 40 covers the edge of the drywall covering 14 to give a finished, attractive appearance, and has another end joined, in a manner to be described, at a joint 50 to a facing or tongue member 51 extending part way across the end of the wall 12. The female portion 38 has a casing member 52, like the casing member 40, which has an end 54 that rests against the other side of the wall 12 and is formed with sections 56, 57, and 58 and joints 59, 60, and 61 as will be described, and another end joined in a manner to be described at ajoint 62 to one end of a facing or jamb member 64 extending part way across the end of the wall 12 toward the tongue member 51.

An L-shaped member has sections 71, 72, and 73 formed in joints 76 and 77 in a manner to be described. The outer surface of the section 71 of the L-shaped member 70 is joined such as by gluing to the end 80 of the facing or jamb member 64. A flat reinforcing strip 84 is glued to the back of the facing member 64 and the end 86 of the section 71 of the L-shaped member 70, and extends across the end of the wall 12 a distance substantially equal to that of the L-shaped member 70, thus defining with the L-shaped member 70 a groove 90 for receiving the end of the tongue member 51.

As shown in FIG. 2, the section 71 of the L-shaped member 72 extends within the doorway opening a distance past the outer surface of the facing member 64 to form a shoulder or stop 92 against which the outer edge of the door 30 rests when closed, thus forming a doorstop, jamb, and casing as an integral assembly.

Shims 96 are placed as necessary between the end of the wall 12 and the reinforcing strip 84, and nails 98 driven through the casing portions 40 and 52, and through the L-shaped member 70, tongue member 51, reinforcing strip 84, and shims 96 into the wall 12 for securing the door and jamb assembly in place.

It is a primary feature of this invention that each of the male and female sections 36 and 38 ofthe jamb assembly is formed and preassembled as a one-piece integral unit, and the hinges 32 premounted to the door 30 and jamb member 64 to minimize installation at the job site; Another primary feature is that the entire assembly is a prefinished wood base structure eliminating theneed for finishing after the assembly is installed, each of the male and female sections 36 and 38 covered with a suitable film layer, preferably of vinyl, as will be described. Even the heads of the nails 98 are prefinished to match the color of the jamb and door so that not even touch-up finishing is required after the unit is installed.

Referring to FIGS. 5 and 6, there is shown the manner in which the female section 38 of the jamb assembly is fonned. A-flat wood board 100 such as, for example, particle board of an appropriate width necessary to form the end 54, the casing member 52, and the jamb member 64 of the female section 38, is covered on one side with a vinyl layer 102 in a manner conventional in the art. A series of parallel grooves 104, 106, 108, and are cut along the length and completely through the board 100 but not through the vinyl covering 102. The top surface of the board 100 is tapered at the right end as viewed in FIG. 5 to form the end 54 of the casing member 52. Glue is inserted in each of the grooves, and then using the vinyl covering 102 as a hinge, the sections of the board 100 are folded so as to close the grooves and form the joints 61, 60, 59, and 62 of the female section 38. The angle sizes of the grooves and their relative locations are chosen such that when the folds are made the end sections 56, 57, and 58, the casing member 52, and the jamb member 64 are formed.

Referring to FIG. 6 it will be obvious that the L- shaped member 70 is formed in a similar manner starting with a flat board 112 having a vinyl covering 114 and parallel grooves 116 and 118 which when covered with glue and closed form the joints 76 and 77, respectively, of the L-shaped member 70. Next, the end 80 of the jamb member 64 is joined such as by gluing to the vinyl covered surface of the section 71 of the L-shaped member 70, and the reinforcing strip 84 is glued to the back of the jamb member 64 and the end 86 of the L- shaped member 70 as shown in FIG. 2.

The male section 36 is formed in the manner shown in FIG. except, of course, the member 64 would be wider to form the tongue member 51.

As seen in FIG. 2 the tongue member 51 and groove 90 are each made to extend sufficiently across the end of the wall 12 such that the end of the tongue member 51 is free to position itself within the groove 90 to accommodate walls of varying thicknesses.

INSTALLATION The unit is packagedwith each male and female section 36 and 38 .of each jamb segment 15, 16, and 17 preformed and prefinished as heretofore described, and with the door prefinished to match that of the jamb assembly and prehung with the hinges 32 mounted to the facing member 64 of the female section 38 in either a right-hand or left-hand door configuration as desired. The female sections 38 of the jamb segments l5, l6, and 17 are joined first by the screws 24 provided to form the mitered joints 20 and 22. Each of the segments l5, l6, and 17 are precut to the correct length and with mitered ends to form the joints 20 and 22. Appropriate screw holes for the screw 24 are also provided in exact alignment to form the joints. The male sections 36 are assembledin a similar manner. Next, the assembled female sections 38 are placed within the rough wall opening with the ends 54 flush against the surface of the wall. Shims 96 are placed between the end of the wall 12 and the female sections as necessary, and particularly at the locations .of the hinges 32 and where the nails 98 will be driven through the tongue and groove, to solidly support the jamb assembly to the wall. Prefinished nails 98 are driven through the casing member 52 into the wall l2 to hold the female section in place.

The assembled male sections are then mounted as a unit with the tongue member 51 inserted into the groove 90 of the assembled female sections and the ends 42 of the male sections resting flush against the opposite side of the wall 12. The prefinished nails 98 are driventhrough the casing member 40 into the wall 12, and also through the L-shaped member 70,- the tongue member 51, the reinforcing strip 84, and the shims 96 to firmly secure the casing assembly to the wall. Several such nails are driven around the casing assembly at the locations of the shims. With this, the entire installation is complete and the assembly ready for use.

From the foregoing it is obvious that a novel door and jamb assembly has been described which provides a minimum of installation time and eliminates the need for finishing at the job site, which is formed in a novel manner to greatly reduce its cost and provide exceptional durability, which is attractive, which is adaptable to fit a variety of wall thicknesses, and which insures a near perfect fit each time, as well as provides the other novel features set forth herein.

Various changes and modifications may be made in this invention, as will be readily apparent to those skilled in the art. Such changes and modifications are within the scope and teaching of this invention as defined by the claims appended hereto.

What is claimed is:

1. An adjustable preformed doorjamb assembly having a wood particle board base construction for mounting in a rough opening of a wall, said assembly comprising a first section having a casing member and a tongue member joined thereto forming at the joint an outer comer, the casing member covering the edge of one of the outside surfaces of the wall, the tongue member extending from the casing member part way across the end of the wall, a second section having a casing member and a facing member joined thereto forming at the joint an outer corner, the casing member covering the edge of the other outside surface of the wall, the facing member extending from the casing member part way across the end of the wall toward the tongue member, a groove member attached to the second section at the end of the facing member opposite the casing member, the groove member having a groove of generally U- shaped cross section adapted to receive an end portion of the tongue member, the length of the tongue member and depth of the groove being such as to provide varying degrees of insertion of the tongue member into the groove between preselected limits to provide adjustability of the doorjamb assembly to accommodate any wall thickness within a predetermined range, the bottom and outer sides of the groove member being joined at an outer comer with the bottom of the groove member extending outwardly past the outer surface of the second section facing and defining a doorstop surface,.each of the first and second sections being preformed as an integral, one-piece unit from a wood particle board base material covered with a prefinished flexible film laminate, the outer comer joints of each of the sections being closed and glued V-shaped grooves in the particle board but not through the laminate with the angle of each V-shaped groove being chosen to form the required corner angle, the laminate acting as a hinge about which the grooves are closed to form the outer corners, whereby each section is completely covered with the prefinished film laminate which extends continuously over the outer corners, and whereby the result is an adjustable, preformed, two-section jamb assembly which is both completely prefinished and of inexpensive particle board construction.

2. The doorjamb assembly of claim 1 wherein for at least one of the casing members a portion of its edge furthest from the opening is folded, by means of V- shaped grooves formed in the particle board base, under and back on itself to rest against the outside surface of the wall.

3. The doorjamb assembly of claim 2 wherein the length of the folded back portion is sufficiently great to receive a nail therethrough for securing the casing to the wall.

4. The doorjamb assembly of claim 14 including a door premounted to the facing member of the second section.

reinforcing strip extending past the one leg of the L- shaped member toward the first section to define with the L-shaped member the groove for receiving the tongue member.

7. The doorjamb assembly of claim 14 wherein the film laminate is vinyl. 

1. An adjustable preformed doorjamb assembly having a wood particle board base construction for mounting in a rough opening of a wall, said assembly comprising a first section having a casing member and a tongue member joined thereto forming at the joint an outer corner, the casing member covering the edge of one of the outside surfaces of the wall, the tongue member extending from the casing member part way across the end of the wall, a second seCtion having a casing member and a facing member joined thereto forming at the joint an outer corner, the casing member covering the edge of the other outside surface of the wall, the facing member extending from the casing member part way across the end of the wall toward the tongue member, a groove member attached to the second section at the end of the facing member opposite the casing member, the groove member having a groove of generally U-shaped cross section adapted to receive an end portion of the tongue member, the length of the tongue member and depth of the groove being such as to provide varying degrees of insertion of the tongue member into the groove between preselected limits to provide adjustability of the doorjamb assembly to accommodate any wall thickness within a predetermined range, the bottom and outer sides of the groove member being joined at an outer corner with the bottom of the groove member extending outwardly past the outer surface of the second section facing and defining a doorstop surface, each of the first and second sections being preformed as an integral, one-piece unit from a wood particle board base material covered with a prefinished flexible film laminate, the outer corner joints of each of the sections being closed and glued V-shaped grooves in the particle board but not through the laminate with the angle of each V-shaped groove being chosen to form the required corner angle, the laminate acting as a hinge about which the grooves are closed to form the outer corners, whereby each section is completely covered with the prefinished film laminate which extends continuously over the outer corners, and whereby the result is an adjustable, preformed, two-section jamb assembly which is both completely prefinished and of inexpensive particle board construction.
 2. The doorjamb assembly of claim 1 wherein for at least one of the casing members a portion of its edge furthest from the opening is folded, by means of V-shaped grooves formed in the particle board base, under and back on itself to rest against the outside surface of the wall.
 3. The doorjamb assembly of claim 2 wherein the length of the folded back portion is sufficiently great to receive a nail therethrough for securing the casing to the wall.
 4. The doorjamb assembly of claim 14 including a door premounted to the facing member of the second section.
 5. The doorjamb assembly of claim 4 wherein the door is prefinished in a selected manner.
 6. The doorjamb assembly of claim 14 wherein the groove member includes an L-shaped member, means joining the outside surface of one leg of the L-shaped member to the end of the facing member, and a reinforcing strip secured to the back of the facing member and the end of the one leg of the L-shaped member, the reinforcing strip extending past the one leg of the L-shaped member toward the first section to define with the L-shaped member the groove for receiving the tongue member.
 7. The doorjamb assembly of claim 14 wherein the film laminate is vinyl. 